Ferrocement Water Storage Tanks for

Rain Water Harvesting in

Hills & Islands
P.C. Sharma
Retd. Head, Material Sciences & Project Leader NDWM Projects, Structural Engg. Research Centre Ghaziabad (India)
Consultant, Rain Water Harvesting & Concrete Technology
Editor New Building Materials & Construction World
165 Jullena, Adjacent Escorts Heart Institute, New Delhi-25, E-mail: nbmcw@vsnl.com

ain water harvesting has a special

importance for hill areas and
islands as it can solve the
drinking water problem of population
living there. Since water recharging into
ground is difficult and an immediate
existing need for drinking water can be
met by storing it in suitable and safe
storage structures during rain. This
stored water is consumed during dry
spells. Families residing in these areas
(mostly in scattered locations) can
harvest Rain water using their roof tops
and court yards, easily and successfully.
As an active participating research
institution in the National Drinking water
Mission (RGNDWM now) programme of
Govt. of India, Structural Engg. Research
Centre Ghaziabad developed and
demonstrated several types of
Ferrocement Structures like tanks upto
25000 ltr. Cap, filters, checkdams,
underground water barriers, etc. for Rain
Water harvesting schemes. Simple, easy
to learn and Practice techniques for
casting and installing F.C. Tanks and
filters were developed and demonstrated
in many NDWM, unicef and 35 point
action plan projects in H.P., U.P. hills,
Assam, Nagaland, Manipur, Meghalaya,
M.P., Rajasthan, A.P., Andamans &
Lakshdeep etc.

The paper presents details for

construction techniques for F.C. Tanks
upto 10000 litre capacity, F.C. Filters
suitable for Roof top R.W.H. Systems for
individual households, schools,
community Bldgs. etc. for solving
Drinking water problem in hills and
islands.
Water storage Tank and Filters are the
two major cost components of a Roof
water harvesting and storage system.
The other requirement are Roof, Gutters,
Inflow Pipe, bypass. Tanks can be
constructed in Rectangular, Cylindrical
or Spherical shapes using steel,
Reinforced cement concrete, Fiber
Reinforced plastics. Brick/stone
masonary, Ferrocement etc. Studies
carried out during NDWM, Unicef and
35 point action plan projects have
confirmed that Ferrocement Tanks are the
lowest cost options in urban and rural
sites. Apart from cost the fast
construction speed is an added
advantage.

What is Ferrocement?
Ferrocement is a durable long lasting
cement based composite material modified form of reinforced cement
concrete in which the reinforcement is
finely subdivided and dispersed in the
matrix in order to achieve a closely

spaced crack regime coupled with

excellent corrosion resistance and high
impermeability to ingress of water. The
matrix of the composite is modified
cement based microconcrete/mortar
prepared using ordinary portland cement
(33 & 43 gd), well graded medium silt free
coarse sand, specially formulated
admixtures containing bonding agents +
plasticizer + poresealent and water.
Techniques and equipment for vibrating
the thin ferrocement layers (including an
orbital vibrator and a medium frequency
surface vibration device) have been
developed by author for use in
ferrocement jobs. The orbital vibrator
developed is suitable for working over
vertical and horizontal surfaces. Fig. 1 (a)
& 1 (b) shows cross section of two
ferrocement units.
Developed in 1847- First Patent in Name
of Fericement by JF Lambot 1853 - used
by Italian Arch P.L. Nervi for construction
of Roofs, Swimming Pools & large size
boats in Italy & European countries in
194049 Period. Lot of R&D work has
been taken up at various Research
Institutes and Universities to understand
the properties and behaviour of this
material in countries like India, Poland,
USSR, USA, Thailand, New Zealand and
Singapore, China etc. and the material is
well accepted as an efficient low cost
appropriate construction material.

(a)

(b)

Fig.1: Cross Section of Ferrocement

SERC (R/G) was actively engaged in R&D

work and dissemination of this
technology in India and other Asian
countries from 1966 to 2000 and
developed large number of applications
for housing, water & sanitation and repair
& rehab of structures.

Constituents of
Ferrocement
Cement - sand - water mesh reinforcement skeletal reinforcement chemical admixtures
The thickness of ferrocement elements
generally varies from 10 mm to 50 mm
whereas for water proofing, rehabilitation

& retrofitting it varies from 16 mm to 50

mm depending upon type of structures
and site specific requirements. In
ferrocement construction the minimum
mesh reinforcement provided is 0.3% by
volume. This may change depending
upon the nature of job. 2 to 6 layers of
hot dip annealed galvanized mesh
reinforcement has been found to be
adequate in most of the cases, Minimum
cover to outermost layer of wire meshes
is usually 4 to 5 mm which has been found
to be enough due to use of fine grain
polymer modified matrix.

Applications
Roofing units - wall panels - water
storage tanks - septic tanks - bins manholes and covers - boats / barrages
pontoons - sinage items - underground
water barriers - check dams - biogas
plants - complete housing units - drainage
/ irrigation units - precast culverts / pipes
- canal lining - wood substitute items like
doors / windows frames and shutters furniture -fins waterproofing /
strengthening / retrofitting of structures
etc.

Merits of Ferrocement
as Structural
Construction
Material
Ferrocement has proved to
be an ideal Construction /
Rehabilitation / Lining
material due to its following
propertiesHigh Compressive,
Tensile, Shear strength and
ability to resist shocks &
vibrations. Excellent
impermeability to ingress of
water even in high water head
position. Excellent
resistance to cracking.
Capability of improving some
of the mechanical properties
such as tensile, shear, impact
& fatigue of materials used
for
construction
of
structures due to developing

Fig. 2: Semi Mechanised Process for Producing

Cylidrical F.C. Units (Patented Revised)

an excellent bond with the substrate practically acts as a monolithic

combination to the surface over which
applied. Excellent corrosion resistance
in wet and low temperature conditions.
Flexibility for further modifications or
repair of ferrocement is easy in case need
arise. Imposition of its little additional
dead load, requiring no adjustments in
the supporting structure. The dead load
in case of an existing over head RCC
water reservoir will be almost equal to
the thick finishing (plaster) applied inside
which is removed for applying lining.
Ability to withstand thermal changes
very efficiently. Readily available
constituent materials. No need for
heavy equipment like concrete mixer /
vibrators. Cost effective and long
lasting life Environment friendly - do
not use fuels, lubricants and does not
release or generate toxic fumes / gasses
or solid waste Can be adopted for
community projects as beneficiaries can
be trained in its construction easily and
quickly and they can provide solid input
in the developmental activity.

Durability
Many Structures constructed or treated
with ferrocement in India in 197374
period are still in excellent performing
condition. The development was
encouraged by the fact that there were
many very old ferrocement boats (Now
more than 120 year old) placed in
European museums. These cases can be
considered as examples of durability of
ferrocement construction.
Many large F.C. Dome structures
constructed in 1976 at B.M. Instt.
Ahmedabad by SERC & Sarabhai
Technology Dev. Syndicate faced the
Gujarat Earthquake without showing
even a single crack. A SHANKH of very
large size and large number of domes have
been constructed at Manan Dham
Ghaziabad using Ferrocement. Very large
number of structures have been treated
for Waterproofing 10 to 20 years ago and
are without any problem. Large number
of these are basements and water bodies.

(11)

(6)
(1)
(12)

(7)

(13)

(2)

(8)
(14)
(3)

(9)
(4)

(15)

(10)

(5)

Figure 3

(16)

Ferrocement Tanks
(17)

Ferrocement, a cement based composite

construction material - modified form of
reinforced cement concrete has been
found to be an effective & durable
construction materials. It has been very
widely used for construction of water
retaining structure such as tanks. The
technique is very suitable for use in
construction of Storage Tanks in Rain
Water Harvesting schemes in Hills, Plains
& Islands as it involves simple procedure
for construction and easy to find
materials.

(18)

Casting of Segmental Base

for Cylindrical Ferrocement
Units
(19)

Segmental
F.C. Roof for
Cylindrical
Units

Ferrocement tanks are being used all over

the world for domestic / industrial &
commercial purposes, In India SERC
(R/G) developed designs and
construction Techniques for Tanks of up
to 25000 litre capacities for NDWM,
Unicef, CSTE Shimla, CSTE Shillong
which could be constructed using local
masons after short span training. Design
packages were prepared and handed over
to these organisations and the
technology provided has been
extensively used.

Why Ferrocement for

Tank Construction
In addition the merits of Ferrocement
explained earlier in this paper it is :-

(20)

Figure 3

Use for Repair & Rehab of existing Masonary /

Steel/ RCC Tanks
Ferrocement has been successfully used in Repairing / leakproofing/Retrofitting of
existing leaking / distressed tanks.

* Free from problems of corrosion,

leakage & seepage * Cost effective lowest cost tanks for storage of drinking
water. * Minimum Maintenance Need.
* Retain Quality of drinking water * Cast
at Site - No Transport Problems. * Lighter
than RCC and masonary Tanks.
* Reduced cement consumption when
compared to RCC & Masonary. * Occupy
less space than RCC and masonary
Tanks. * Easy to repair by local
technicians - Even Accidental damages
due to hitting of a rolling stone from hill
slope can be repaired easily. * Do not
need concrete mixers or vibrators and can
be constructed in Remote areas. * Do not
require shuttering - No Electricity
needed. * Provide employment to local
technicians and labour. * Can be finished
and Painted to match any environment.

Design of F.C. Tanks

A Diploma holder in Civil Engg. can carry
the design of F.C. Tanks by using
developed procedures. Ref - 2,12, 13 &
14 provide design procedures and details
for Reinf, size shape & casting method
for F.C. Tanks & Filter for RWH system.
Fig. 4

Fig. 5

Fig. 6

* Larger tanks can be cast in segments

and transported to sites for fast erection.
* Technology already demonstrated in
large number of states hence master
masons available. * Double wall insulated
tanks can be constructed for subzero
areas.
Precaution
* Need some care in construction &
Initial training for masons & supervisors.
* Painting of inside with Drinking Water
Tank Paint once in 10 years.
Expected Functional Life - 35 to 40 years

The Casting
Technology
F.C. tanks are produced using skeletal
cage plastered by hand method in most
of the countries outside India. The
thickness for such units comes to about
30 mm even for smaller capacities and
casting speed is also slow. The author
and his group at SERC (R/G) improved
the casting system and bought the
minimum thickness to 20 mm for tanks
upto 2500 l. capacity. The time taken in
casting was also reduced to all most half.
For overcoming these problems, the
author at SERC (G) developed three
casting techniques for fabrication of walls
for cylindrical F.C. tanks upto 25,000 litre
capacity. Use of SERC techniques result
in reduction of wall thickness,
improvement in compactness of mortar,
improved performance, reduction of
construction time and cost when
compared to the traditional casting
system. Two of these processes (given
on sl. 1 & 2) are covered by Indian Patent
No 145250 and have been released to
more than 75 licencees through NRDC,
New Delhi.
Tanks cast with semi-mechanised process
and segmental system light being thin
walled and are assembled using prefabricated components. Tank base
generally cast using R.C.C. but can be
cast with ferrocement for capacities upto
5,000 litres. Tank walls are cast using
either of the three casting methods :
A. Semi-mechanised process for
producing F.C. cylindrical units.
B. Precast segmental shell elements
casting and assembling these into
cylindrical units.
C. Tempformer method for casting walls
of ferrocement tanks.

Fig. 7

Fig. 8

Fig. 9

SERC SemiMechanised Process

for Cylindrical Tanks
In the semi-mechanised process a simple
hand operated equipment (Fig. 2) is used
in which the galvanised woven wire
fabric (square woven mesh) from a tightly
wrapped roll is continuously wound on
to a cylindrical fast openable mould made
of wooden frame body covered with G.I.
sheet. Rich cement and sand mix
designed to obtain a compressive
strength 250 kg/cm2 at 28 days is applied
on each layers of mesh continuously. The
Mesh end is anchored to the mesh layer
below by stitching. The Mould is opened
after 18 to 24 Hrs. depending upon the
weather. The Roof, lid for the Tank are
cast over masonary moulds and base is
precast using steel moulds placed over
Levelled Floor. Inlet, outlet, scouring and
overflow sockets are cast while casting

the wall or the mesh area at their locations are left unplastered for
fixing these at the time of assembling. Because of Mechanised
casting the walls for tanks upto 2500 litres cap could be cast 12
mm thick.

SERC Precast Segmental Shell

elements casting and assembling
process
Suitable for mass production, long distance transfers and erection
over multi storeyed bldgs or in hill areas and islands. Segments of
a cylinder with designed reinforcement meshes projecting on both
sides for subsequent field assembling, are cast (designed
thickness - 10mm) over permanent or temporary moulds.

Fig. 10: Dimension and Other Details for 10,000 lit.

Capacity F.C. Tanks.

The total circumference of the cylinder is divided into 3, 4, 6, 8, 12

or 16 segments. These units are cast separately and cured for
about 7 days and then transported to site. The precast units have
reference number marked over these. The base concrete is cast
using designed reinforcement and segmental units are placed
vertically over the premarked wall point & held in vertical position.
Wire mesh laps (as per design) for projections on both sides are
fixed. M-25 grade mortar/microconcrete is impregnated into the
cage and extra mesh layers are fixed over joint portion and mortar
applied over these meshes also. Fig 3(1) to 3(18) show different
stages of segmental casting process. Base and Roof for segmental
tanks can also be cast in segments and assembled jointed at site
Fig. 3 (19) & 3 (20) show Tank Roof cast in segments. Fig. 4 show
finished 10000 ltr. tanks cast using segmental technique.

Tempformar Technique
When large number of same capacity Tanks are required use of
tempformer technique saves time in construction, ensured proper
shape, uniform thickness of casting. Tempformer are inside moulds
made using light section wooden scantlings and light gage G1
sheet. Fast to assemble and dismental Tempformers were
developed at SERC for NDWM project and were used in NE Area.
As the cost of these units is low and also distributed on large
numbers of cast units these donot add much cost to tank cost.
Fig. 4 show the technique.

Skeletal Cage Technique

Also known as Traditional Technique for FC Tank Construction Steps
Decide the size according to capacity and follow a proper design

for the capacity selected.

Select a place nearest to catchment, level and make a platform at

Fig. 11: Reinforcement Details for Wall & Base of 10,000

lit. Capacity F.C. Tank.

least 30 cm above ground level.

Mark Reinf. Pattern on ground and fabricate the skeletal cage First the base and then wall cage. Remember to provide proper
laps in steel bars and wires. Join the base and wall cage properly.
Fix woven wire square mesh of size given in Drg. - Provide
minimum lap of 100 mm at all mesh joints number of mesh to be
as per design.

and cross supports on outside the

tank.- Mortar may be applied in two
layer one from top and another
from bottom. A 30 gage G1 sheet
piece is held against the mesh for
applying the mortar. The opening
the central manhole and opening
for filter are left unplastered.
Once the Roof plaster is over,
the Filter body is erected and fixed
at its opening.
Fig. 6, 7, 8, 9 shows stages of
skeletal cage construction. Fig. 10,
11 & 12 shows details of
Reinforcement & dimensions for a
10000 ltr. tank. Author has
developed two vibrators for
improving the compactness in
skeletel cage casting system. This
reduces the mortar consumption
and thickness.

Fig. 12: Details of Roof for 10,000 lit. F.C. Tank.

Fix, in let out, scouring and overflow

sockets.
Make a earthen mould for the dome

shaped Roof - Cover it with polythene

sheet and prepare the roof cage.
Cast the base portion using 1 : 2 : 3 mix
cement concrete using 8 mm and down
grade aggregate compact it properly also make sure the cover below base
reinforcement.
Apply a Thin layer of microconcrete
on wall Reinf - cage and cover the inner
mesh layer to vertical reinf. Rod.
Wait for 18 to 24 hrs and apply one
layer of mortar and one layer of mortar
on exterior surface making up the
designed thickness.
Finish Base wall joint and cover the
corner with microconcrete - wait for 24
hrs.
Lift the Reinf. cage of Roof, keep in
position connect to vertical walls
provided in wall - Fix temp supports
below the Roof cage to keep it in
desired shape.
Apply mortar without climbing over
cage. For this purpose make a temp.
supporting arrangement using vertical

Social Aspects of
Ferrocement Tank
Technology

Ferrocement is a labour intensive

Technology & the skills involved can be
learned easily by unemployed rural youth
and even by women.
This has made Community Participation
Possible in Rural Development and water
projects. The total unskilled manpower
can be tapped from local source by
involving beneficiaries. Local masons,
smiths are good enough to produce
ferrocement structure under supervision
of a Trained member
of the same group.
This has been
successfully
demonstrated in
remote areas of hills
in
Manipur,
Meghalaya
&
Islands
like
Andamans
and
Lakshdeep.
The technology
provide employment
to
unemployed
youth and improve
their skills for future
use.

F.C. Tanks are cheapest and easiest to

construct and Maintain even in difficult
areas. Amount of materials required is
small hence less problems of handling
and transport.

Effectiveness of
Technology is Cost
Reduction
Based on field studies carried out as Part
of Unicef project & CSTE project in
Himachal Pradesh. Table 1 Provides cost
data for a comparison.

Ferrocement Filters
Ferrocement Filters are cast using
skeletal cage technique or are precast
over masonry moulds. Circular filters of
500 to 900 mm dia and depth of about 700
mm are adopted. Fig. 10 Provides details
of a F.C. Filter and bypass arrangement.

Conclusion
Ferrocement Tanks are the most
economical structures for storage of
drinking & water. If constructed using
proper design & construction technique
the life span can be upto 50 years.
SERC (G) is not available for technical
help now but New Building Materials &
Construction World (a Civil Engg. journal
published monthly from Delhi) is
providing technical support to agencies
interested in construction of Ferrocement
Structure. Tel.: 011-26841228,
Fax: 26832424

Treatment for Repairing of 50,000

gallon O.H. Water Tank, Journal of
Ferrocement, Vol. 14, No. 3, July 1984.
7. P.C. Sharma Ferrocement Segmental
Shell - a Multipurpose Unit, Asia
Pacific Symposium on Ferrocement
Application for Rural Development,
Roorkee (India), April 1984.
8. P.C. Sharma Construction Techniques
for Ferrocement Application, Asia
Pacific Course on Ferrocement
Technology, April 1984, Roorkee, 1984.
9. P.C. Sharma, Ferrocement Water Tanks
for Safe Storage of Drinking Water,
National Workshop on Water Mission
at C.S. & M.C.R.I., Bhavnagar, 1012
April, 1987.
Fig. 13

References
1. P.C. Sharma and others Small capacity
ferrocement water tanks, proceedings
of 8th session of IASS Committee of
Pipes and Tanks, Budapost, Hungary,
June 1978.
2. P.C. Sharma and V.S. Gopalaratnam
Ferrocement Water Tanks - Do it
Yourself Book, International
Ferrocement Information Concrete,
Asian Institute of Technology,
Bangkok, Thailand, 1978.
3. Watt S.B. Ferrocement water tanks and
their construction, Intermediate
Technology Publications Limited,
London, 1978.
4. P.C. Sharma Construction of
Ferrocement Water Tank using Skeletal
Cage and Hand plastering System,
Technology package given as course
material in training courses conducted
for National Drinking Water Mission
& Unicef on Construction of Rain
Water Collection System and
Ferrocement Water Storage Structures
between January 1987 to December
1991
5. P.C. Sharma Ferrocement Lined Brick
Masonary - Manual Prepared Tanks
at SERC, Roorkee / Ghaziabad January,
1987
6. P.C. Sharma & others Ferrocement

10. P.C. Sharma, Ferrocement Structures

for Islands and Remote Areas, I.A.S.S.
Conventional on Technology for
Remote Areas, New Delhi, 23 May,
1998.
11. P.C. Sharma & J. Swarup,
Construction Techniques for F.C.
Water Storage Tanks, Symposium on
Water and Sanitation Services in Asia
and the Pacific, Kualalampur,
Malaysia, 1115, 1988.
12. P.C. Sharma, H.V. Krishnaswamy Technology Package on Rain Water
Harvesting
Structures
for
implementation of RWHS Programme
on a large scape in Himachal Pradesh UNICEF Delhi Project - 1996.
13. P.C. Sharma - Technical Package, Rain
Water Harvesting Schemes for Towns
in Himachal Pradesh - including
detailed designs - Project Sponsored
by State Council for SC. & Technology
Shimla, H.P.
14. P.C. Sharma - Ferrocement Storage
Unit (Ferrocement Bhandaran Patra) Do
it yourself Manual on water Jars 400 to
1500 lit. capacity - Containing
Procedure suitable for Rural woven on
self help basis.